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Polymers 2017, 9(2), 77;

Enhanced Injection Molding Simulation of Advanced Injection Molds

Department of Polymer Engineering, Faculty of Mechanical Engineering, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
Department of Materials Science and Technology, Széchenyi István University, Egyetem tér 1, H-9026 Győr, Hungary
MTA–BME Research Group for Composite Science and Technology, Műegyetem rkp. 3., H-1111 Budapest, Hungary
Author to whom correspondence should be addressed.
Academic Editor: Xianqiao Wang
Received: 13 January 2017 / Revised: 13 February 2017 / Accepted: 17 February 2017 / Published: 22 February 2017
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The most time-consuming phase of the injection molding cycle is cooling. Cooling efficiency can be enhanced with the application of conformal cooling systems or high thermal conductivity copper molds. The conformal cooling channels are placed along the geometry of the injection-molded product, and thus they can extract more heat and heat removal is more uniform than in the case of conventional cooling systems. In the case of copper mold inserts, cooling channels are made by drilling and heat removal is facilitated by the high thermal conductivity coefficient of copper, which is several times that of steel. Designing optimal cooling systems is a complex process; a proper design requires injection molding simulations, but the accuracy of calculations depends on how precise the input parameters and boundary conditions are. In this study, three cooling circuit designs and three mold materials (Ampcoloy 940, 1.2311 (P20) steel, and MS1 steel) were used and compared using numerical methods. The effect of different mold designs and materials on cooling efficiency were examined using calculated and measured results. The simulation model was adjusted to the measurement results by considering the joint gap between the mold inserts. View Full-Text
Keywords: injection molding; direct metal laser sintering; injection molding simulation; conformal cooling; high conductivity copper alloy injection molding; direct metal laser sintering; injection molding simulation; conformal cooling; high conductivity copper alloy

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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Zink, B.; Szabó, F.; Hatos, I.; Suplicz, A.; Kovács, N.K.; Hargitai, H.; Tábi, T.; Kovács, J.G. Enhanced Injection Molding Simulation of Advanced Injection Molds. Polymers 2017, 9, 77.

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